Dry-particle based adhesive and dry film and methods of making same
View Patent ↗Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.
1. A process for manufacturing a cathode for use in a lithium ion battery, comprising:
supplying dry carbon particles and dry metal oxide particles;
supplying a dry binder consisting essentially of fibrillizable binder particles;
dry milling the dry carbon particles, dry metal oxide particles and dry binder in the absence of solvent and additional binders to form a powdered dry cathode mixture including fibrillized binder;
feeding the powdered dry cathode mixture including the fibrillized binder to a compactor to form a self-supporting dry film; and
applying the dry film to an electrically conductive substrate to form the cathode.
2. The process of claim 1 , wherein the metal oxide particles comprise lithium metal oxide particles.
3. The process of claim 2 , wherein the lithium metal oxide particles comprise at least one of lithium cobalt oxide and lithium manganese oxide.
4. The process of claim 1 , wherein the dry carbon particles comprise intercalated carbon particles.
5. The process of claim 1 , further comprising calendering the powdered dry cathode mixture prior to applying the dry film to the electrically conductive substrate.
6. The process of claim 5 , wherein the calendering comprises compressing the powdered dry cathode mixture in a roll mill.
7. The process of claim 6 , wherein the roll mill is a heated roll mill.
8. The process of claim 1 , wherein applying the dry film to the electrically conductive substrate comprising laminating the dry film to the electrically conductive substrate.
9. The process of claim 1 , wherein the dry binder consists essentially of polytetrafluoroethylene (PTFE).
10. The process of claim 1 , wherein the dry milling comprises jet milling.
11. The process of claim 1 , wherein the carbon particles comprise conductive carbon.
12. The process of claim 1 , wherein the carbon particles comprise graphite.
13. The process of claim 1 , wherein the carbon particles comprise carbon black.
14. The process of claim 1 , wherein the dry binder consists essentially of a fluoropolymer.
15. The process of claim 1 , wherein the powdered dry cathode mixture comprises up to 10% dry carbon particles, 50% to 96% dry metal oxide particles, and 0.5% to 30% fibrillized binder.
16. The process of claim 1 , wherein the dry film has a compression density greater than or equal to 0.45 gm/cm 3 .
17. The process of claim 1 , wherein the electrically conductive substrate comprises a metal foil.
18. A method of manufacturing a lithium ion battery comprising:
making a cathode according to the process of claim 1 :
providing an anode; and
placing the cathode and the anode into a housing with electrolyte.
19. The method of claim 18 , wherein the anode comprises a milled dry mix of dry carbon and dry binder consisting essentially of fibrillated binder.
20. The method of claim 19 , wherein the anode comprises a dry mix of 80% to 96% graphite, up to 10% carbon black, and 4% to 10% fibrillated binder.
21. The method of claim 18 , wherein providing the anode comprises:
dry milling second dry carbon particles and a second dry binder in the absence of solvent and additional binders to form a powdered dry anode mixture including fibrillized binder;
feeding the powdered dry anode mixture including the fibrillized binder to a compactor to form a second self-supporting dry film; and
applying the second dry film to a second electrically conductive substrate to form the anode.
22. The method of claim 18 , wherein the anode comprises a lithium metal foil.
23. The method of claim 18 , wherein the electrolyte comprises acetonitrile.
24. The method of claim 23 , wherein the electrolyte comprises tetrafluoroborate in an acetonitrile solvent.
25. The method of claim 18 , wherein the electrolyte comprises tetramethylammonium.
26. The method of claim 18 , wherein the electrolyte comprises carbonate-based electrolytes.
27. The method of claim 26 , wherein the electrolyte comprises at least one of ethylene carbonate, propylene carbonate, and dimethylcarbonate.
28. The method of claim 18 , wherein the electrolyte comprises an alkaline water solution.
29. The method of claim 28 , wherein the electrolyte comprises at least one of potassium hydroxide (KOH) and sodium hydroxide (NaOH).
30. The method of claim 18 , wherein the electrolyte comprises an acidic water solution.
31. The method of claim 30 , wherein the electrolyte comprises sulfuric acid (H 2 SO 4 ).